Abstract:
A rechargeable metal-air battery having a housing, an air flow path, and at least one metal-air cell positioned within the housing. An air movement device communicated with the housing. The metal-air cell generates oxygen and hydrogen during cell charging. The air movement device creates a pulsating air flow within the air flow path for directing a flow of the generated gases.
Abstract:
A ventilation system for a metal-air battery having a housing for enclosing at least one metal-air cell (10). The housing (20) has at least one air inlet opening (30) and at least one air outlet opening (35). A fan (40) is positioned to force air into the air inlet opening and out of the air outlet opening when the fan is turned on. The openings are sized with a length in the direction through the thickness of the housing being greater than a width in the direction perpendicular to the thickness of the housing. The openings are unobstructed and are sized to eliminate substantially the air flow into the air inlet opening and out of the air outlet opening when the fan is turned off. According to another aspect of the invention, a fan (80) within the battery housing (72) is positioned to distribute air to two separate sets (76-79) of metal-air cells at the same time. In this configuration, all cells of both sets of cells receive air quickly, and the air received is richer in oxygen because the air paths are shorter than in previous configurations utilizing the same number of cells.
Abstract:
A dual air electrode metal-air cell having a casing including an upper cathode mask wall, a lower cathode mask wall, and a plurality of side walls; a metal anode with at least upper and lower sides covered with separator materials; an upper air cathode positioned between the upper cathode mask wall and the separator materials on the upper side of the anode; a lower air cathode positioned between the lower cathode mask wall and the separator materials on the lower side of the anode; a gas vent positioned on one or more of the side walls of the casing; and a liquid electrolyte substantially trapped by the separator materials. The separator materials comprise one or more layers of an absorbent fibrous web and one or more layers of a microporous membrane that, when wet, is gas-impermeable and liquid-permeable.
Abstract:
An anode for use in an electrochemical cell comprising a current collector layer having a thickness less than about 10 mils, and desirably less than about 4 mils, and a rigid support extending adjacent one side of the current collector layer so that the current collector layer is sandwiched between the anodic layer of the anode and the rigid support. The rigid support maintains the current collector layer in the original configuration of the current collector layer during discharge and recharge cycles of the cell. A cell containing the anode is also disclosed. The rigid support for the anode current collector can be mounted in the electrochemical cell case so as to allow for the release from the cell of gas produced at the anode.
Abstract:
An air manager system (10) for a metal-air cell (20) having an air cathode (28) is provided to control air and moisture admitted to the cathode. The air manager system optimizes the use of ambient air and reactant air utilized by a metal-air cell by recirculating (40) the reactant air and admitting (46) only a sufficient amount of oxygen from the ambient air to generate the necessary output for the battery. The present invention also provides a method of recirculating the ambient air while admitting only an amount of ambient air sufficient to replace oxygen that has been used by the cell during operation. The present invention also provides an oxygen supply (42) control circuit which increases or decreases the oxygen available to the metal-air cell based on load demand so as to provide further moisture control. The oxygen control circuit also adjusts the air inlet valve (47) to an optimum setting based upon the particular mode of operation of the load. The invention further provides a cathode plenum (39) having an inlet (42) and outlet (47) and a plurality of baffles (68) defining a nonlinear path, essentially covering the entire surface area of the cathode (28), for the air to flow from the inlet to the outlet in a turbulent manner.
Abstract:
A bifunctional airelectrode for use in electrochemical energy cells discharges a satisfactory current on the first discharge cycle and operates for a relatively large number of charge-distance cycles without gas forming between the electrolyte side of the air electrode and the electrolyte. The active layer of the electrode includes an oxygen reduction catalyst having a first oxygen evolution potential and an oxygen evolution catalyst having a second oxygen evolution potential less than the first oxygen evolution potential, the oxygen reduction catalyst being present in a greater concentration proximate the electrolyte side than proximate the air side and the oxygen evolution catalyst being present in a greater concentration proximate the air side than proximate the electrolyte side.
Abstract:
A cathode cover for a metal-air cell of the type having an air cathode positioned along an external surface of a cell case provides for improved control over exposure of the air cathode to air. The cathode cover allows a sufficient amount of air to the air cathode for an adequate production of power from the cell but limits the amount of air to which the air cathode is exposed so as to prevent premature failure of the cell from flooding, drying out, or contamination. In addition, the cathode cover avoids the problems of point diffusion of oxygen through the air cathode and localized electrolytic reactions. The cathode cover includes a mask member defining a plurality of openings therethrough and forming at least one substantially unobstructed air chamber between the mask member and the air cathode. The mask member includes at least about three of the openings per square inch of the air cathode and the openings provide between about 0.001 and about 0.01 square inches of total open area per square inch of air cathode. In addition, the air chamber has at least about 0.033 cubic inches of unobstructed volume per square inch of the air cahtode.
Abstract:
A metal-air battery pack is disclosed for external assembly to a portable electronic device with a battery compartment. The battery pack electrically connects to the electronic device through an existing connector of the device that is located in the battery compartment of the device. Another aspect of the present invention provides a palm rest as part of a battery for a portable computing device.
Abstract:
A vent system for exhausting gas generated within a battery case is provided. The vent system exhausts gas from the battery case while maintaining the hermetic seal of the case. The vent system provides a small gas exit hole that is sufficiently small to prevent electrolyte leakage and also intake of excess carbon dioxide or excess water vapor from the atmosphere. Also, various combinations of gas-permeable, hydrophobic membranes and diffuser material may cover the gas exit hole to provide humidity control for the battery while exhausting gases from the battery. A recess may be provided within the case such that the gas exit hole communicates between the atmosphere and the recess. Also, various combinations of gas-permeable, hydrophobic membranes and diffuser material may cover the recess and gas exit hole to provide humidity control for the battery while exhausting gases from the battery case. The present invention also provides a vent system in which gas-permeable, hydrophobic membranes and diffuser material may fill an opening so as to exhaust gas from the case. The present invention also provides an electrode lead which extends along the battery case and through the seam of the battery case in a manner in which a hermetic seal is provided around the lead. The manufacturing process for the seal around the lead is relatively simple.
Abstract:
An air manager system is disclosed which maintains a more stable water vapor and carbon dioxide equilibrium across the air cathode of a metal-air cell while still providing new oxygen needed for operation of the cell at desired power levels. Oxygen is preferentially drawn in through one or more ventilation openings (17) in a housing (15), so that the concentrations of water vapor and carbon dioxyde in the battery housing remain more stable, resulting in less transfer across the cathode (30). A fan (20) circulates the gases within the battery housing, keeping the oxygen needed for operation of the cell in contact with the air cathode even though the oxygen concentration within the housing is reduced compared to the ambient air outside the housing. Therefore, the cell is less susceptible to drying out or flooding, and less carbon dioxyde intrudes into the cell.